Apparatus for shaping materials



Oct. 23, 1951! J. J. KOWALEWSKI APPARATUS FOR SHAPING MATERIALS FiledMay 19, '1949 5 Sheets-Sheet l INVENTOR. JOHN J KOWALEWSK/ 91M42 J. J.KowALEwsKl 2,572,267 APPARATUS FOR SHAPING MATERIALS Oct. 23, 195] 5Sheets-Sheet 2 Filed May 19, 1949 INVENTOR. JOHN J. KOMLEWSKI BYATTORNEK Oct. 23; 1951 J. .1. KOWALEWSK! 2,572,267

APPARATUS FOR SHAPING MATERIALS INVENTOR.

JOHN J KOMLEWSKI BYMJ. Z

ATTORNEY J. J. KOWALEWSKI APPARATUS FOR SHAPING MATERIALS Oct. 23, 19515 Sheets-Sheet 4 Filed May 19, 1949 mmvrm JOHN J KOWALEWSKI W ATTORNEYJ. J. KOWALEWSKI APPARATUS FOR SHAPING MATERIALS Oct. 23, 1951 5Sheets-Sheet 5 FiledMay 19, 1949 Illlllllllll I V D 0 mmvrox.

JOHN J KOWALEWSKI 3W M ATTORNEK Patented Oct. 23, 195i UNITED STATESPATENT orrlcr.

APPARATUS FOR SHAPING MATERIALS John J. Kowalewski, Bronx, N. Y.,assignor to Electrolux Corporation, 01d Greenwich, (John, a corporationof Delaware Application May 19, 1949, Serial No. 94,204

7 Claims. 1

This invention relates to a machine for automatically shaping elongatedwork pieces, such as metal strip brush elements, into predeterminedstar-shaped or similarly conformed units. More particularly, it embracesa metal shaping device for strip brush elements wherein the metallicbrush strip is press fitted intoconformal contact with the surfacecontour of a star-wheel and held in close contact therewith untilrelatively permanently set, whereupon it is stripped from the star-wheeland emerges in the form of a continuous spiral comprising a plurality ofconvolutions each of which can be cut and mounted to make individualrotary brush units.

It is an object of this invention to provide a device for forming anelongated work piece such as a strip brush element into a continuous andhelically shaped body from which single unit turns may be cut to formindividual star-shaped brush elements suitable for attachment on artatable mounting head for floor, furniture, etc, polishing devices.

A further object is to provide an apparatus for making brush elementscontinuously and with a minimum of waste of the brush forming materials.

Still another object is to provide an easily operated automatic devicefor making rotary brush elements, a device operable by anyone having thecustomary skill of the conventionally trained production line industrialworker.

Still other and further, objects will become apparent and otherwisesuggest themselves to those skilled in the art upon reading thedescription of the invention herein given.

To this end the invention is particularly described-herein as applied tothe manufacture of rotary floor polishing brush units. However, it is tobe understood that the examples given are merely illustrative and arenot to be construed as limiting the invention.

The improvements and advantages of the present invention are morereadily appreciated when considered in conjunction with the appendeddrawings forming a part of this description and in which:

Figure 1 is a front perspective view of the entire apparatus inassembled condition, showing one of the cam units broken away anddisplaced forwardly on a broken axial line in order to show detailedconstructional features more clearly;

Figure 2 is an exploded view takenfrom the same position as Fig. 1 butsomewhat enlarged and showing the relationship of the various in-"Iternal constructional elements making up the device;

Figure 3 is a front plan view of the apparatus with the cover plate,holding pawl, front cam unit, and brush lifting plate for the completedbrush removed;

Figure 4 is a rear perspective view showing the gear train andrelationship of the driving parts, the side plate being removed; and

Figure 5 is a partial sectional View taken on the line 5-5 of Fig. 3showing, however, all the dismantled parts in their proper orientationfor actual operation.

Briefly, this invention contemplates, in one of its aspects, a methodandapparatus for press fitting a metal strip brush element intoreentrant portions or indentations cut in the periphery of a rotatingtemplate, i. e., star-wheel, with the aid of cylindrical brush shapingelements which are sequentially inserted, removed and reinserted intoconformally cut indentations in the template while the latter iscontinuously rotated.

This invention is predicated on the utilization of the phenomenon ofcold flow in metals. The apparatus embodies a work piece shaping wheelhaving indentations or reentrant portions into which the work piece inthe form of a brush strip is press fitted and conformably cold pressedto assume the desired design, after which it is removed by being liftedoutwardly in the form of a helical spirally shaped body in onecontinuous piece.

The particular embodiment of the reentrant type of brush shown in thedrawings may be variously modified. In some brushes, a more acutebending may be desired, in others, fewer reentrant portions may beutilized. In any embodiment the particular shape of the structureadopted is determined by the purpose which the brush is designed toserve.

Referring now in more detail to the embodiment shown in the accompanyingdrawings, Fig. 1 and more especially to Fig. 4, the particular devicetherein illustrated comprises a side plate 15, Fig. 1, a front plate I6and'a, rear plate, [1, Fig. 4, with hollowcylindrical collars orseparating pillars l8 mounted therebetween. The whole assembly is heldtogether by bolts I9 which pass from the outer surface of the plates andthrough the hollow pillars l8, forming a strong supporting framework. j

The various elements comprising the brush forming device are mounted byappropriate shafts bearinged in the respective front and rear plates.

Thus a drive shaft bearinged in bracket 2| which is mounted on the rearof front plate It is driven through reduction gearing by an appro priatepower source such as an electric motor (not shown) and has a worm gear22 affixed to its inner end. Gear 22 operatively engages sprocket 2:1afiixed to shaft 25. Shaft 25 is bearinged in front and-rear plates, l6and IT, respectively, and has affixed on its front end, a pair of cammembers 26, 2!, Figs. 1 and 2, which actuate ram 28 through contactingrollers, 29 and 39. respectively, on pin 3! in a reciprocal motion alongram guides 32, 33.

A train of gears at the rear-of plate l 'i operates to rotate the brushforming elements in synchronism with the ram 28. Thus pinionflll ani xedto shaft 25 engages idler spur gear 42 afiixed to shaft 53 which in turnengages gear 44 afflxedto shaft 45 on the other end of which brushforming starwheel 50, Fig. 2, is. affixed. The. completely formed brushelementis shaped by forced conformal contactwith the contour ofstar-wheel 5%). The brush strip 100, Fig. 1, enters as astraight brush.elementthrough guide rolls.35 mounted on a freely rotatable pivotmember 36 ahead of a reciprocating plunger or ram 28.0perated insynchronisrn with the presentation of appropriately. contoured reentrantportions l5l, Fig. 2, of the star-wheel 59; In order that theretractionof the plunger 28 does not. effect an accompanying return of .the formedstrip brush to its previous relatively straight shape, the. plungeraction. is effected'while providing for. the insertion ahead of it of aroller element 2, Fig. 2,. having a cylindrical surface conforming witha. predetermined portion of the reentrantsection [52 of the starwheel,the brush beingpinched .between the two conforming surfaces; 'Pawl means82, Fig. 5, is provided to maintain the roller. 2 in position Within thethusnewly enteredreentrant portion I52 of the star-wheel-Bfi and duringthe. with drawal or retraction ofthe plunger28. anduntil the roller isadvancedby'thereentrant portion into contact witha fixedroller retainingguide member, namely. the inner or concave surfaceof guide 52. Thus .apredeterminedportion of-the brush piece under pressureis molded into aset andpermanent shape conforming to the corresponding portion of'theoutersurface orcontour of the star-Wheel contacted thereby.

After the star-wheel-has advanced a sufficient distance to enablethelformed brush to assume a permanent set and to eliminate any tendencyofa the. .formed brush element to-lift oif thesurface of the contourwheelQand-partially reassumeitsformer straight shape, the previouslyinserted roller brush" forming elements-must be removed one by onefromtheir immediately associated reentrant portions of the star-wheel andreturned for subsequent reinsertion intoa new and subsequently presentedreentrant position along the contoured surface'of the star-wheel.

In order to effect the.-desiredrecurrent use ofthe cylindrical brushshaping elements, a number, i. e. fourteen-(Ito ldginclusive,see Figs.2, 3)" in all, of these cylindricalelements are -.used, at most three ofwhich are retained at any one time in actual brush forming or brushshaping position within the arms or fingers of the star Wheel 50. Thethreebru shshaping cylinders, 2,- 3- and 4, Fig. 2,- are. caused toremainbetween their immediately adjacent arms-ofthe starwheel 5ll byridingalong the inner or-concave sideof guiding cam .52 for apredetermined porend of their useful functioning, these cylindricalelements are lifted from their immediately assoelated reentrant portionsof the star-wheel by means of extracting cam '5].

Cam 5: together with the convex side of inner guide 52 and the frontfacing plate I6 serves as a magazine for storage and conveyance of thecylindrical shaping elements around the convex surface of inner guide52. It is through this conveying means that these cylindrical elementsare led bael; one by one through the magazine to positions forsynchronized sequential remsertion intobrush form-mg position 'and intoalignment withacorresponding and subsequently presented reentrantportion of star-wheel 50.

In this deyice the shaped and formed brush strip continues in contactwith the conforming surface of star-wheel 50 until it contacts brushlifting plate 55 at its lower cam portion 56 which latterextendsbehindthe base/portion I02, Fig. 2,

of thecompletelyformed and finally shaped por tionof the finisheclbrush,forcing it axiallyand laterally. out of the. path of the peripheryof-the star-Wheel 58 and lifting it from the outer circumference ofthestar-wheel and out of the path of the. newly presented portion of.the incomingbrush strip. I00.

A pawl .80 fulcrumed on front plate 15- in hingemembersti holds theinserted'cylindrical members in location between apair of arms orfingersof star-wheel 50. afterthe ram 28 positions them substantially intotheir appropriate reentrant positions, e. g., cylinder 2 in reentrantsection- 152, Fig. 2, and holdsthem place until further rotation ofthestar-wheel 50 advances the-inserted cylinder to ride on theinner-concave face- Pawlsively long cam surface whereby ram 28 is heldin its most remotely advanced or cylinder holding position. Thus, usingholding pawl 80-, ram.

28 can be. retracted immediately and the-high portion or dwell of camsurface 26 canthus be considerably shortened.Simultaneouslytheretraction of ram 28 leaves a space vacant for thesubsequent insertion of the next cylinder, i. e. number I, into thenextreentrant portion; i. e.

number I51, of star-wheel 5|] and thus-into brush shaping position aheadof ram 28.: This-also-permits the advancement of the remainingcyli-ndersthrough the magazine under-the terminal pressureof the lastextracted-cylinder,- i. e. number 4, at'the end of itsbrush formingstep.

In operation, a straight or. similar stripty-pe of brush blank Hlilisinserted'by one end-thereof into the space between the pivoted guiderolls'35 and from this point-the brush passes down-between theoutercontour of star-wheel 58 and a partially inserted cylinder,- 2;Fig. 2.

brush backing. .l G 0,. pinching. the latter "firmlyinto place withinreentrant portion I52; the starwheel 58; is rotated continuously-untilthe entirebrush striphas passed through the machine and is lifted out bycam 55. This results in -the-p roduction of a spirally shapedcontinuously formed helix, each convolution of 1 which may besubsequently cut and fitted together at the ends to;

form ample brush stock for a single rotary-brush.

'2- Such a brush is suitable for mountingin-a frame tion of ,arevolution of the star-wheelim At the 7;; five unit type of brush isshown, by simply vary- Afterthecylinder 2 is pressed home againstthe'metaliicentire process.

ing the contour of the star-wheel 50 and correspondingly varying theother brush forming elements, I to I4 inclusive, various other types anddesigns of rotary brush elements may be,

obtained, and in a manner similar to that described above. In any event,the completely formed brush comes off the contoured wheel as a helicalstructure from which individually circular-shaped brush elements arereadily cut.

The extracting or ejector cam 5| guides the cylindrical rolls, 1. e. 4through I4, into a storage and conveyor magazine formed by the concaveside of outer guide track 5| and the convex side of inner guide track 52both of which tracks are fixedly mounted by machine screws 90 on theface of front plate I6. A cover plate 62 held in place by screws 9| ismounted over the two guide tracks and completes the enclosed magazinechamber through which the brush forming cylinders are conveyed back intoposistrip into the star-shaped forming wheel at the proper angle. Theguide rolls pivoted at 36 enable the brush strip I to swing freely inaccordance with the angle made by the forming edge of the star-wheel,thus making necessary one and only one bend in the brush stock.

The forming rolls, I to I4, contacting the brush in sequence keep thelatter from springing or distorting back into any semblance of itsformer more straightened condition prior to insertion or passage overthe star-shaped contoured wheel. By lifting the shaped brush up theincline of the stripping cam 56, a slight camber is given the brushwhich enables it to come off in a helical form Illl and thus lifts itfree of the star-shaped wheel. Thus, from each strip, five, six or moreindividual rotary brushes may be made, depending on the length of theoriginal straight brush strip I00.

The slight internal camber 58, Fig. 5, of the star-wheel together withthe diminished size of the inner portion 59, Fig. 5, of the cylinderforming members I to I4 serves to hold the metallic portion I02 of thebrush strip I00 firmly in place against the contoured surface of thestar-shaped brush forming wheel 50. This structure insures an uprightbrush structure, unaccompanied by any excessively distorted edge efiector twisting of the brush bristles, thereby assuring an even distributionof load over the entire brushing surface when mounted for use.

The use of the holding pawl 80 for maintaining the newly insertedforming cylinder in its advanced position, see Fig. 5, makes possiblethe immediate return of the plunger or ram 28 from its most advancedposition as in Fig. to its lowermost dwell on the camming'surface, thusspeeding up the process of insertion of a new cylindrical element andthus accelerating the The slightly beveled lower edge 85, Fig. 2 of pawl80 facilitates the insertion of the next cylindrical member, i. e.number I Fig. 2, by forcing pawl 80 outwards and compressing spring bias86 against stop 81. Stud screw and lock nut 88 provide the means foradjusting the depth of insertion of pawl 80 within opening 89 in coverplate 62.

The embodiment of the invention illustrated in the drawings anddescribed in detail has been adduced merely for the purposes of showinga serting the elements into the reentrant portions,

means for guiding a work piece in between the elements and the surfaceof the contoured means, means for removing the elements from thereentrant portions after the shaping of the work piece, and means forremoving the formed Work piece from the surface of the contoured means.

2. Apparatus for shaping elongated work pieces such as strip brush unitsinto coils of reentrant form having a succession of reversebends,'comprising a Wheel having a predetermined contour of star shapeand including reentrant portions, elements conformal with said reentrantportions, means for inserting said elements into conformal relation withthe reentrant portions of the wheel, means for rotating the wheel intimed relation with the means for inserting said elements into thereentrant portions of the wheel, means for guiding a work piece inbetween the elements and said reentrant portions, means for removing theelements from the reentrant portions after the shaping of the workpiece, and means for lifting the formed work piece from the contourof'the wheel.

3. Apparatus for shaping elongated work pieces such as strip brush unitsinto coils of reentrant form having a succession of reverse bends,comprising a wheel having a predetermined contour of star shape andincluding reentrant portions, elements conformal with said reentrantportions, means for inserting said elements into conformal relation withthe reentrant portions of the wheel, meansf or rotating the wheel intimed relation with the means for inserting said elements into thereentrant portions of the wheel, means for guiding a, work piece inbetween the elements, and said reentrant portions, means for removingthe elements from the reentrant portions after the shaping of the workpiece, means for lifting the formed work piece from the contour of thewheel, and means for conveying the removed elements back into positionfor reinsertion into conformal relation with the reentrant portionsof'the wheel.

4. Apparatus for shaping elongated work pieces such as strip brush unitsinto coils of reentrant form having a succession of reverse bends,comprising a wheel having a predetermined contour of star shape andincluding reentrant portions, elements conformal with said reentrantportions, means for inserting said elements into conformal relation withthe reentrant portions of the wheel, means for holding said insertedelements in position while the inserting means is retracted forreception of a subsequent element, means for rotating the wheel in timedrelation with the means for inserting said elements into the reentrantportions of the wheel, means for guiding a work piece in between theelements and said reentrant portions, means for removing the elementsfrom the reentrant portions after the shaping of the work piece, andmeans for lifting the formed work piece from the contour of the wheel.

5. ,Anp ratusfor h p nei loneet dwer u eees Such as n izush units.ntewils nset-Wren form having a succession of reversehends, comprising aw el' ins a ede rmined contour f. tar; hape nd; n din ntr nt; p tions mets. con o l w th {said ee rant PQKQQQ means for inserting said, elementsinto conformal trant ;portions of the wheel, freely, pivoted means.

for guiding a work piece in between then-elements andsaid reentrantportions, means for removing the elements from the reentrant portionsafter the shaping of the work piece, and means for liftingthe formedwork piece from the contour of the rwheel.

Apparatus for shaping elongated work pieces ,having a succession ofreverse bends, compr rig a wheel having a predetermined contour ofstanshape; and including reentrant portions, elements conformal withsaidreentrant portions, meansforinserting said elements into conformalrelation with the reentrant portions or the wheel, eeeentric oam meansfor actuating said element inserting means, pawl means for holding saidinsertedelements in position while the inserting means is retracted forreception of a subsequent element, means for rotating the wheel in timedrelation with the means for inserting said elemer ts.- into.thereentrant portions of the wheel,

h..as,strip brush unitsinto coils of reentrant.

freelypivotedmeansior guiding a workpiece in between theelementsand saidreentrant ortions, means fer removing the elements from the -reen trantportions after the shaping-of thework piece, and means for lifting theformed piece from the contour ofthe wheel.

7, Apparatus for shaping elongated workpieces such as strip brush unitsinto; co i1s -of -reentrant form having a succession of reyerse;bends,com-.- prising, an oscillatory ram, a star-shaped wheel hayingreentrantportions and being mounted in cooperativeassociationwiththeram, an eccentric cam for moving the ram in timed rela tionwith-thereentrant portions. of the wheel,- a plurality ofroller elementsadapted for sequential in sertion between the ram and the reentrant portions-v of the wheel, means for guiding a strip brush work piece. inbetween the roller elements and thewheel, means for operating theeccentric REFERENCES CITED The following; referencesare of record in thefile ofv this patent:

UNITED STATES PATENTS Number, Name. Date 137,827 Clark Apr. 15; 18,73"1,987,334, Geer, Jan. 8, 1935

